Cover installation system for open topped containers

ABSTRACT

A cover system for covering open topped containers such as truck trailers carrying particulate material such as dirt, gravel, grain and the like. The cover is a flexible sheet material sized to cover the open top and can extend over the end and down the sides of the container, if desired. A roller is provided at one end of the open top for rolling up the cover to store the cover with the top open. A transverse rod runs through a hem at the opposite end of the cover. Edge guides on the rod maintain the cover in alignment with the container top when the cover is unrolled over the top. At least one freely rotatable roller or slide is provided on the rod near the rod center. A rope, strap or the like is secured to the rod to pull the rod and cover over the open top. The roller or slide allows the leading end of the deploying cover to ride up and over any heaped granular material in the container to avoid the edge digging into the material, which could prevent further deployment of the cover and could result in spillage of material forced onto the top of the cover.

This application is a continuation-in-part of Ser. No. 08/579,245 filedDec. 27, 1995.

BACKGROUND OF THE INVENTION

This invention relates in general to covers for large open toppedcompartments and, more specifically to a system for installing a coverover a container where the contents extend above the container.

Open topped compartments, such as truck trailers, dump trucks, storagebins and the like used for hauling or storing particulate material suchas grain, ash, lime or the like are subject to having the material fallor blow out onto the roadway. Exposure to rain, excessive sunlight,etc., is often damaging to materials being hauled or stored. Withmaterials such as gravel, aggregate or similar materials, havingportions of a load fall onto a roadway is undesirable both from thepoint of view of littering and the danger of the material striking afollowing vehicle, possibly breaking a windshield or causing anaccident. Where heated materials, such as asphalt, are being stored orcarried, retention of heat within the container is very desirable.

Many localities now have laws requiring that all open topped vehiclecompartments be covered when containing loose or lightweight material.Often, the loads are simply covered with a tarpaulin that is tied to theedges of the open top at intervals around the opening. While sometimeseffective, such tarpaulins are difficult for one person to put intoplace, especially in windy conditions. Often, it is necessary for theoperator to climb on the vehicle or bin sides or across the load tosecure the tarpaulin, at considerable personal danger. Installation istime consuming and must be carefully done to prevent an edge of thecover from loosening, allowing spillage of part of the load.

Attempts have been made to provide more convenient covers that arerolled or folded at one end of the compartment and can be unrolled orunfolded to cover the load. These arrangements are generally difficultto deploy and do not adequately secure the sides of the cover to thecontainer sides.

Where a container is filled or overfilled with a granular material, suchas dirt or gravel, to the point where the material extends above thecontainer walls, moving a cover over the container surface, typicallyalong and generally parallel with the container upper wall edges, isdifficult. The cover edge moving along the container edges tends to diginto the material. Forcing the cover edge through the material isdifficult, often impossible for a single operator. In addition, some ofthe material may be spilled or end up on top of the cover, defeating thepurpose of the cover, since spilled or loose material on the cover willfall to the roadway, endangering other vehicles and violating laws andregulations governing covered loads.

Thus, there is a continuing need for improvements in deployable coversfor open topped compartments and systems for installing them that willfully and uniformly restrain material loaded in the compartment alongboth the ends and sides of the compartment, can be easily moved into andout of the covering position by one person standing on the ground, willfully cover material that extends above the compartment sides and willavoid forcing heaped material over the compartment side or onto thecover upper surface from which it can fall to the roadway.

SUMMARY OF THE INVENTION

The above-noted problems, and others, are overcome in accordance withthis invention by a cover system for generally rectangular open toppedcompartments which basically comprises a flexible cover sheet sized tocover at least the top of an open top, mechanisms for moving the coversheet from a rolled up, stored position with the top open and uncoveredto a deployed position covering the open top and a means for causing theleading edge of the cover to move up and over any material heaped abovethe top edges of the container. The cover sheet has first and secondends and opposed sides. A tubular means at a first end of the open topis secured to the first end of said cover sheet and is adapted to havingthe cover sheet wrapped therearound.

A transverse rod is secured to the second end of said cover sheetadjacent to the opposed sides of the cover sheet. A deployment means,typically a strap or loop, is secured to the center of the rod forunrolling the cover sheet.

A central guide member is provided on the transverse rod adjacent to thedeployment means so that as said cover is pulled over heaps of granularmaterial in the compartment that extend upwardly above the plane of thetop, the guide will move the transverse rod and cover leading edge upand over the material, carrying said cover sheet edge above the materialand preventing the rod and leading sheet edge from digging into thematerial.

Preferably, the deployment means comprises attachment means such as astrap attached to the center of the transverse rod and a line fastenedto the strap and extending over the end of the container toward whichthe cover is being moved for pulling the cover to the fully deployedposition.

A transverse rod end guide means is provided at each end of the rod forguiding the rod along the container edges during movement of the rod andcover between stored and deployed positions.

The guide member as claimed in this application comprises a tubular hubsurrounding a central portion of the rod, two flanges extend outwardlyof the hub, one extending underneath the cover and one extending beyondthe second end of the cover. A strap is secured to the hub underneaththe second flange. The first flange lies adjacent to the cover and maybe secured thereto if desired or may be left free floating. The secondflange preferably extends upwardly at a small angle, preferably fromabout 5 to 30 degrees.

BRIEF DESCRIPTION OF THE DRAWING

Details of the invention, and of preferred embodiments thereof, will befurther understood upon reference to the drawing, wherein:

FIG. 1 is a schematic side elevation view of a truck trailer using thecover installation assembly of this invention;

FIG. 2 is a perspective view of a cover leading edge sub-assembly with awide cylindrical roller guide means;

FIG. 3 is an exploded view of the rod and roller sub-assembly;

FIG. 4 is a detail view showing an alternate pulling means attachment;

FIG. 5 is a perspective view of a cover leading edge sub-assembly withmultiple rounded roller guide means;

FIG. 6 is a perspective view of a cover leading edge sub-assembly withelliptical roller guide means;

FIG. 7 is a perspective view of a cover leading edge sub-assembly withairfoil-shaped guide means;

FIG. 8 is a perspective view of a cover leading edge sub-assembly withmultiple straight paddle wheel guide means;

FIG. 9 is a perspective view of a cover leading edge sub-assembly withmultiple square cross section roller guide means;

FIG. 10 is a perspective view of a cover leading edge sub-assembly withmultiple spiked cylindrical roller guide means;

FIG. 11 is a perspective view of a cover leading edge sub-assembly withwidely spaced narrow cylindrical roller guide means;

FIG. 12 is a perspective view of a cover leading edge sub-assembly witha sliding panel guide means;

FIG. 13 is a perspective view of a cover leading edge sub-assembly withmultiple curved paddle wheel guide means;

FIG. 14 is a section view taken on line 14--14, but with system in theroll-up mode;

FIG. 15 is a section view taken on line 14--14, but with the system inthe deployment mode;

FIG. 16 is a perspective view taken from above of another embodiment ofa cover leading edge sub-assembly with a sliding panel guide means; and

FIG. 17 is a perspective view taken from below of the embodiment shownin FIG. 17.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

While the cover installation assembly of this invention may be used withany open topped container, including storage bins and the like, apreferred application is covering an open topped cargo compartment oflarge trucks, such as dump trucks and material transporting trucktrailers of the sort schematically shown in FIG. 1.

Trailer 10 includes a generally rectangular container 11 having highsides 12 with an open top and is adapted to be moved by a conventionaltractor 14. Container 11 may have an openable rear side panel and aconventional hydraulic lift mechanism (not shown) to lift the front endand cause granular material to slide out the back. Any suitable granularor particulate material may be carried by such a trailer, such as dirt,sand, gravel, grain, etc.

In order to prevent a load of granular material from having particlesblown out of container 11 or, where heaped above the sides 12, slideover a side during truck movement it is desirable (and often legallyrequired) that a cover 16 be installed over the open top of container 11whenever trailer 12 is moved. A particularly effective cover arrangementis detailed in copending U.S. patent application, Ser. No. 08/258,933,filed Jun. 13, 1994. That cover is stored on a roller at one end of acontainer and is unrolled to deploy the cover entirely over the opencontainer top. As described, side flaps may be included, to be deployedwith the cover. That cover arrangement is very effective, in particularwhere the container is filled to a level not above the upper edges ofthe sides 12.

However, with that cover system and many others wherein a cover is movedto the deployed position along the edges of the open top problems mayoccur where the material is heaped above the sides. The leading edge ofthe cover will likely dig into the heaped material, making completion ofdeployment difficult. In addition, some of the granular material may endup on top of the cover, from which it might blow or slide onto theroadway during truck movement.

As seen in FIG. 1, a leading edge guide means, such as an assemblyrollers 18, is provided at the leading edge of the deploying cover sothat when heaped granular material 20 is encountered, the leading edgecan ride up and over the heap. The leading edge guide will also serve topress down on localized heaps of material, helping to spread thematerial so that all of the material is at or below the top edges of thecontainer sides 12. Thus, one person can deploy the cover by pulling onrope 22, where without leading edge guide rollers 18 or the like theleading edge may dig in to the point where deployment by one personbecomes difficult or impossible.

Details of the deployment mechanism and the leading edge guideembodiment comprising rollers 18 are provided in FIGS. 2 and 3.

Cover 16 is formed from a flexible material, typically a fabric orplastic film material. A transverse rod 24 extends through tubular edges26 in portions of cover 16 adjacent to the sheet sides, typically formedby hemming the edge of cover 16. Cover 16 is cut away between these edgeportions to provide room for rollers 18. The deployment means, typicallya rope 22, is secured to a loop 28 of flexible material around rod 24 atthe center of the sheet edge. Alternatively, rope 22 could be a strap,typically having a width of up to about 2 inches and woven from a highstrength material. Such a strap could extend along the end of the coverand be sewn thereto rather than surrounding rod 29, as shown in FIG. 4.

Details of the rod and roller assembly are provided in the exploded viewof FIG. 3. A thin cylindrical rod 24 (only small portions of which areshown for clarity in illustrating the other components) extends throughthe components shown in FIG. 3.

A short tube 30 rotatably fits over rod 24 at the rod center about whichtube 28 rides. A roller 18 is mounted on rod 24 on each side of tube 28.Rollers 18 in this preferred embodiment are made up of a central tube 32and two end caps 34. Tube 32 and caps 34 are formed from any suitablematerial, such as plastic or aluminum. While one roller 18 on each sideof center are preferred, several shorter contiguous tubes could be used,if desired.

An assembly of two washers 36 and spacer 38 is slipped over rod 24 intocontact with the outermost end cap 34 at each side of center. The lengthof spacer 38 is selected to abut the edge 40 of sheet 16 to keep theroller assembly and sheet properly aligned.

At each end of rod 24 a washer 42 and spacer 44 are slipped over the rodto a position abutting the side edge of cover 16. A disk 46 having asmall central hole is held to each end of rod 24 by a bolt 48 threadedinto a corresponding hole in the end of rod 24. Spacer 44 with washer 42and disk 46 form an edge guide that moves along the upper side edge ofcontainer 12 to cause the cover assembly to stay in alignment with thecontainer top opening during deployment and rewinding.

While rollers 18 may have any suitable dimensions, spacing betweencenters of about 50 to 70% of the cover width are preferred for optimumdeployment efficiency.

FIG. 4 shows an alternative embodiment of the means for pulling cover 16over container 11. Here the elongated pulling means is a flat strap 52,preferably having a thickness of 0.1 to 0.2 inch and a width of 0.5 to 2inches, formed from any high strength woven material. Strap 52 extendsover tube or bushing 30 (as seen in FIG. 3) and overlaps cover 16. Theend of strap 52 over sheet 16 is sewn thereto with high strength thread.If desired, a doubler sheet (not shown) may be sewn to cover 16 toenlarge and reinforce the area to which strap 52 is fastened. Thisembodiment has the advantage of avoiding bowing of rod 24 duringpulling.

Several alternative embodiment of the leading edge guide means areillustrated in FIGS. 5-12.

Each of these guide means replaces rollers shown in FIGS. 1-3. In eachof these embodiments, cover 16, transverse rod 24, washers 36 and 42 andtubes 30, 38 and 44 are as discussed above, except that the lengths oftubes 30 and 38 are varied to accommodate the different guideconfigurations.

As seen in FIG. 5, four widely spaced narrow rollers 60, having equallengths and widths, preferably having a generally spherical crosssection in a plane that includes transverse rod 24 are provided.Preferably rollers 60 are spaced approximately equal distances apart,with the outermost rollers spaced apart about 60 to 80% of the width ofcover 16. This embodiment is particularly desirable where rough, largeparticle size material is being carried, such as large gravel and thelike. The narrow, spherical rollers roll easily over such material.

FIG. 6 shows an embodiment using two spaced rollers that have generallyelliptical axial or lengthwise cross sections and generally circulartransverse cross sections. The centers of the rollers are preferablyspaced apart about 50 to 70% of the cover width. While rollers 12 mayhave any suitable dimensions, diameters in the range of about 2 to 6inches, lengths of about 2 to 5 times the diameter are preferred foroptimum deployment efficiency. The sum of the lengths is preferablyabout 30 to 70% of the width of sheet 16. These rollers moveparticularly well over medium sized gravel and the like.

FIG. 7 shows an embodiment using generally tapered, airfoil-like,members 64, which slide up and over heaped material. Members 64 arepivotally mounted on transverse rod 24 which passes through the thickerairfoil leading edge parallel to the leading edge. Best results areobtained where members 64 have thicknesses in the range of about 2 to 6inches and the sum is of the axial lengths of members 64 is about 30 to70% of the width of sheet 16.

An embodiment using paddle wheel guide members 66 is shown in FIG. 8.While flexible or stiff blades 68 may be used, flexible blades thatdeflect only sightly when in contact with a heap of material arepreferred. While rollers 18 may have any suitable dimensions, paddlewheel diameters in the range of about 2 to 6 inches are preferred.

"Rollers" 70 having a generally square transverse cross section areshown in FIG. 9. Although four sides to roller 70 is preferred, anysuitable polyhedral transverse cross section having three or more sidesmay be used as desired. While rollers 70 may have any suitabledimensions, diameters across faces in the range of about 2 to 6 inchesand total axial lengths of from about 30 to 70% of the width of sheet 16are preferred.

FIG. 10 shows an embodiment in which rollers 72 have a plurality ofoutwardly extending spikes 74. Any suitable number of spikes may beused. Preferably spikes 74 extend from about 1 to 3 inches above theroller. Ideally, the rollers 72 have the dimensions mentioned forrollers 18, above. This embodiment is particularly preferred for usewith very soft heaped material, since the spikes will help keep therollers turning and prevent the rollers digging into the heap.

For use with very course, hard heaped material, the embodiment shown inFIG. 11 may be preferred. Two narrow, widely spaced, relatively largediameter rollers 76 are provided on rod 24. While rollers 76 may haveany suitable dimensions, diameters in the range of about 4 to 10 inches,and a transverse width to axial thickness ratio of at least 2 arepreferred.

An embodiment in which a guide means slides up and over heaped materialis shown in FIG. 12. Here, a tubular hub 78 fits around rod 24. Twoflanges 80 and 82 are secured to hub 78 at an angle to each other offrom about 5 to 30 degrees. First flange 80 is fastened to cover 16,such as by adhesive bonding, sewing or the like. Second flange 82 issecured to hub 78 at an acute angle to flange 89 so that flange 82extends upwardly as the cover is drawn over a heap of material in thecontainer, sliding up and over the heap. A strap 84 is fastened to tube78 and/or flange 82 for fastening to a pulling means such as a rope.This arrangement is simple, works especially well with soft material inresisting digging in and will also tend to smooth out the heap.

Another preferred embodiment is shown in FIG. 13-15. This embodiment isgenerally similar to that shown in FIG. 8, except that here the blades sof each paddle wheel 92 are hinged and curved so that the convex side ofeach blade 90 contacts the surface of the heaped material as strap 28 ispulled to cover the load. A flexible material which will bend slightlyin contact with the heap is preferred for best tracking.

An outer tube 93 is rotatably positioned around an inner tube 94. Atleast one, and preferably three as shown, blades 90 have edges 96 with agenerally circular cross section, each fitted in a channel 98 configuredso as to act as a hinge, permitting movement of the blade between thepositions shown in the section views of FIG. 14 (roll-up mode) and thatshown in FIG. 15 (deployment mode).

As seen in section views in FIG. 14, when the paddle wheel assemblies 92are pulled in the direction indicated by arrow 100, paddle wheel 92rotates in the direction indicated by arrow 102 to fold blades 90against tube 93, allowing the assembly to roll alone material 104.

When paddle wheel assemblies 92 are pulled (by pulling on strap 28, FIG.13) in the direction indicated by arrow 106 in FIG. 15, each paddlewheel rotates in the direction indicated by arrow 108, causing the freeedges of each blade 90 to dig into material 104 and open up to a largediameter that permits the assembly to easily climb up and over a heap ofmaterial 104 without pushing the material ahead of the paddle wheels.

FIGS. 16 and 17 shown another embodiment in which the second end ofcover 16 includes a guide means slides up and over a heap of material.This embodiment is generally similar to that shown in FIG. 12.

Cover 16, rod 24, washer 42, spacer 44 and arm 77 (or a disk 46 as seenin other Figures) are the same as the corresponding components detailedabove. Hub 78 has mounted thereon, such as by welding, two flanges 80and 82. First flange 80 extends under cover 16 and may have any suitableshape, such as the triangular shape shown, rectangular, semi-circular,etc. Second flange 82 extends away from the second end of cover 16 at asmall upward angle to flange 80; preferably from about 5° to 30°. Secondflange 82 may have any suitable shape, such as the preferred rectangularshape shown, curved, trapezoidal, etc. Flange 80 may be secured to theunderside of cover 16, such as by adhesive bonding, or may be left freefloating.

Strap 84 is attached to the approximate center of rod 24 and hub 78.Where flange 80 is secured to cover 16, strap 84 can be convenientlyfastened to hub 78 by any suitable means such as rivets, adhesivebonding or attachment to a bracket welded to the hub or screws or boltsextending through hub 78 into rod 42, as desired. Where flange 80 isfree floating, strap 84 may be advantageously attached directly to rod24 by bolts, a bracket or the like extending through hub 78 into rod 24or directly to rod 24 through a cut away opening in hub 78.

While certain preferred materials, dimensions and arrangements have beendescribed in detail in conjunction with the above description ofpreferred embodiments, those can be varied, where suitable, with similarresults. Other applications, variations and ramifications of thisinvention will occur to those skilled in the art upon reading thisdisclosure. Those are intended to be included within the scope of thisinvention as defined in the appended claims.

I claim:
 1. A cover installation assembly for installing a cover over atop of an open topped container which may contain granular materialextending above said open top which comprises:a sheet of material sizedto at least cover said open top having first and second ends and opposedsides; means at said first end of said container secured to said firstend of said sheet for storing said sheet with said open top generallyuncovered; a transverse rod secured to said second end of said sheet; atubular hub surrounding a central portion of said rod; a first flangesecured to said hub and generally parallel thereto and extending alongsaid sheet of material on a side toward said open topped container; asecond flange secured to said hub and generally parallel thereto andextending away from said second end of said sheet at an angle to saidsheet, in a direction away from said open topped container; and andmeans secured at approximately the center of said hub for drawing saidsheet along said container.
 2. The assembly according to claim 1 whereinsaid angle is from about 5° to 30° to said sheet.
 3. The assemblyaccording to claim 1 wherein adjacent surfaces of said sheet and saidfirst flange are secured together.
 4. The assembly according to claim 1wherein said first flange is adjacent to, but free from, said sheet forpivoting movement relative to said sheet.
 5. The assembly according toclaim 1 wherein said means for drawing said sheet along said containercomprises a strap secured to an approximate center of said hub.
 6. Theassembly according to claim 5 wherein said strap is secured to both saidhub and said rod at substantially the center of hub and rod lengths. 7.In a cover installation assembly for installing a cover over a top of anopen topped container which may contain granular material extendingabove said open top which comprises:a sheet of material sized to atleast cover said open top having first and second ends and opposedsides; means at said first end of said container secured to said firstend of said sheet for storing said sheet with said open top generallyuncovered; a transverse rod secured to said second end of said sheet;and means for moving said transverse rod and second sheet end along saidopen topped container and over any material therein; the improvementcomprising:a tubular hub surrounding a central portion of said rod; afirst flange secured to said hub and generally parallel thereto andextending along said sheet of material on a side toward said open toppedcontainer; a second flange secured to said hub and generally parallelthereto and extending away from said second end of said sheet at anangle to said sheet, in a direction away from said open toppedcontainer; and and means secured at approximately the center of said hubfor drawing said sheet along said container.
 8. The improvementaccording to claim 7 wherein said angle is from about 5° to 30° to saidsheet.
 9. The improvement according to claim 7 wherein adjacent surfacesof said sheet and said first flange are secured together.
 10. Theimprovement according to claim 7 wherein said first flange is adjacentto, but free from, said sheet for pivoting movement relative to saidsheet.
 11. The improvement according to claim 7 wherein said means fordrawing said sheet along said container comprises a strap secured to anapproximate center of said hub.
 12. The improvement according to claim11 wherein said strap is secured to both said hub and said rod atsubstantially the center of hub and rod lengths.